WELCOME

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 PRESENTED BY M.JAWAHAR .B.E
ASSISTANT INSPECTOR OF FACTORIES

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MATERIAL HANDLING
Handling of materials is an inevitable function
in any walk of work in any industry

35 to 40 % accidents occurs due to bad method

of material handling
TYPES OF MATERIAL HANDLING

  I . Manual handling

  II. Mechanical handling

  III.Automation

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 I. MANUAL HANDLING

 Human energy

 Used for lifting or

 Carrying of Material

 25 Million Man days lost

 annually Due
 to back pain

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 `
Incorrect handling of Has Identified as a contributory factor in the majority
products and materials been of minor accidents and minor injuries in workplace

PRINCIPLES OF CORRECT HANDLING

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 FACTORS INFLUENCING THE HANDLING

Weight
What Character
Why Size
When Shape
MATERIAL Distance
Where HANDLING
Who Purpose
How Cost
Route
 Frequency
Quantity
FLOW OF MATERIALS THROUGH SHOP

Straight line Zig –Zag U-Shape Circular

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 Some of the Accessories used in Manual Handling
®I.Hand lift trucks

® ii. Dragging rollers

®iii. Sliding rollers

®Iv.Wheel barrows

®v. Hand trucks

® vi. Pulley block

Vii.Shovel

viii.Hooks

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 Characteristics of Material Handling Equipments

Material Bulk Packaged

Movement Vertical Horizontal Combination of

both

Supervision Required Close Little Equipment is

automatic or semi
auto
Path followed Variable Fixed Fixed area

Speed Variable Fixed Either fixed or

variable

Power required for the operation of Electrical Manual I.C.Engine Gravity

equipments

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Functions and principles of good Material Handling

Minimize the movements involved

in a Production operation

Aim at moving optimum number

of pieces in one unit

use the principle of containerization

unit load or palletization

Safe,standard,efficient,effective
appropriate,flexible and proper sized
Material handling equipment should be selected
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Employ mechanical aids in place of manual labour
in order to speed up the material movements

®changes in sequence of production operations may be suggested in

®order to minimize back tracking and duplicate handling

Handling equipments arrangements should minimize distances moved

by products and at the same time handling equipments should not
interfere with the Production line
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 Utilize gravity for assisting material movements wherever possible

 Design containers,packages,drums etc

 economic handling and to reduce
 damage to the materials in transit

Material handling equipments should

periodically by resorted to check ups
repairs and maintenance

 Minimize the distances moved

 by adopting shortest routes
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 Factors to consider are
1.weight of the load 2. Shape and size of the load

3.Height of the load 4. Material the load is made of

5.condition of the floor 6.available headroom

7.material in which the load is contain 8.space around the load

9.Temp.of the room in which

the load is stored 10.lighting conditions

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 Types of injuries caused due to manual handling
i.Bruisers ii.Burns iii.Cuts

Disorders of the back include

a) Strains and bears of tendons ,ligaments and muscles

(tendons : tough fibrous cord fastening a muscle to a bone)
(ligaments : a band of fibrous tissue banding two bones)

b) Prolapsed inter vertebral disc(‘ slipped disc ‘ )

c) lumbago :
a term descriptive of severe lumber pain

d) rheumatism :
particularly in joints

e) fracture/compression of the spinal cord ; and

f) hernias

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Causes for accident in manual handling

 A) Unsafe postures

 B) improper lifting

 C) Heavy loads

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Causes for accident in manual handling

 D) unsafe grip

 E) self stability

 F) group in compatibility

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 G) using personnel protective equipments

Different types of
helmets face shields
and goggles

Different types of gloves

aprons,shoes and safety belts

Different type of
ear muff, ear plugs
and respirative
equipments
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II.MECHANICAL HANDLING
Appliances engaged in mechanical handling
i. Lifting appliances
a)Lifting machines
b)Lifting tackles

ii. Conveyers

iii.Fork lift truck

iv. Pay loaders

v. Power trucks

vi.Tractors and Trackers 17

 I. LIFTING APPLIANCES
a) Lifting machines Crane
Hoists
Chain pulley blocks
Jib cranes
Motored pulley block

Chain hoist

Jib crane Electric hoist

Gantry crane Air hoist

Bridge crane

Shackles
Lifting clamps
b) Lifting tackles Wire rope sling
Chain sling 18
 I. LIFTING APPLIANCES
Crane
a) Lifting machines Hoists
Chain pulley blocks
Jib cranes
Shackles
b) Lifting tackles Lifting clamps
Motored pulley block

Wire rope sling

Chain sling

All lifting appliances should bear the following markings

i. Identification mark or number

ii. Safe working load (SWL)

iii. Date of proof of load test

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 WIRE ROPES
CONSTRUCTION OF WIRE ROPES

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 WIRE ROPES
CONSTRUCTION OF WIRE ROPES

Ordinary

Seale

Warrington

Filler

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TYPES OF LAY

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 WIRE ROPES
MEASURING THE WIRE ROPE

INCORRECT CORRECT

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 WIRE ROPES
INSPECTION OF WIRE ROPES

•BROKEN WIRES

•WORN OUT WIRES

•REDUCTION IN ROPE DIA.

•ROPE STRETCH

•BIRD CAGE

•KINKS

•CORE PROTRUSION
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WIRE ROPES
BROKEN WIRES

•6 OR MORE BROKEN WIRESIN ONE LAY

•3 OR MORE BROKEN WIRES IN ONE
STRAND IN ONE LAY
•MORE THAN 5% IN ANY LENGTH OF 10
DIAMETERS

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 WIRE ROPES
WORN AND ABRADED WIRES

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 WIRE ROPES
REDUCTION IN ROPE DIA.

REPLACE THE WIRE ROPE IF THE DIA REDUCES BY

•1mm FOR ROPE DIA UPTO 19mm

•1.5mm FOR ROPE DIA UPTO 22-38mm

•2mm FOR ROPE DIA UPTO 32-38mm

ROPE STRETCH

150 mm PER 30m LENGTH OF SIX STRANDED ROPE

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WIRE ROPES
BIRD CAGES

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WIRE ROPES
CORE PROTRUSION

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THUMB RULES FOR FINDING SWL

Wire Rope:

SWL = 8*D*D
D = dia. of the rope
eg: 1/2” rope dia = 8 *1/2 *1/2 = 2MTons.

Note: Dia is in inches & result in Tons.

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‘U’ CLAMPS

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 STRENGTH OF WIRE ROPE
SWL OF MECH. HAND BULLDOG CHOKER
WIRE ROPE SPLICED SPLICED GRIPS HITCH

100% 95% 80% 80% 80%

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FIBER ROPES
1. Manila Rope

2. Jute rope

3. Nylon Rope

4. Polypropylene Rope
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 SLINGS
TENSION ON SLINGS

If L is greater than S
then sling angle is OK 34
SLINGS - HITCHES

BRIDLE HITCH

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SLINGS - HITCHES
BASKET HITCH

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SLINGS - HITCHES
CHOKER HITCH

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 If you force the eye
down

450

Get severe Let the eye ride higher and keep this
loading in angle approx. 450 or more
slings because
of low sling
angles

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RIGGING PRACTICES

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 RIGGING PROCEDURES

 Planning

Skill gang - Leader

Rigging equipments

 Inspection procedure –

Once in a month-color code

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Electrical lines

Weather condition
Wind force
Night shift

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 Center of gravity

Stability of Load

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 RIGGING PRECAUTIONS

Sharp Bends , Pinching &

crushing –avoid for slings –
provide packing- curve 7 lays

Never wrap a wire rope

around a hook.

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 Ensure that slings are protected at
all sharp corners on heavy items

For heavy structural

members

Radius of contact
should be equal to 1
rope lay

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Do not permit bending near
any splice or attached fitting

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RIGGING PRECAUTIONS
LIFTING BY CRANE

Suspended loads –securely slung & properly balanced

Tag Line
Safely landed & blocked
Lifting beams –SWL marked.
Hoist rope – don’t wrap it around the load.
Multiple part lines –don’t twist
Slack rope condition –ensure it is seated properly on
the drum
Stand clear of the load
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Whenever 2 or more ropes Use of tag lines to control all loads
are to be placed over a
hook - use a shackle

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50
 RIGGING PRECAUTIONS
Erection
Before lifting check the sling is properly attached to the
rope.
Avoid impact / jerk load
Never ride on a load
Never allow load to be carried over the head of personnel
Never work under suspended load.

Ensure all personnel stand clear while load is lifting,

lowered and the sling is removed.

Never leave a load suspended in air when the crane/ hoist

is unattended.
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 Before being unhooked all Stay away from slings when
loads must be safely landed they are being pulled out
and properly blocked from under loads

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 RIGGING PRECAUTIONS
ERECTION
No temporary repairs on slings

In multi leg slings –secure the unused slings.Never

point load a hook

Remove or secure all loose materials from the load

Ensure load is free before lifting & all legs are taking
the load.

Lower the loads on to adequate blocking to prevent

damage to the slings.

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On a Rigid object the load could be Know what the load in each sling
carried on only 2 legs or sling while leg will be before the lift is made
other legs only serve to balance

The tension in
Carrying Full load the most heavily
loaded legs is
Balancing more important
than the total
weight

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 CONVEYERS
TYPES OF CONVEYERS

I. Wheel conveyer 2.Apron conveyer

3.Screw conveyer

4.Pusher bar conveyer 5.Pneumatic conveyer 55

.Pivoted bucket conveyer .Trolley conveyer

Belt conveyer

.Spiral chute conveyer

CONVEYERS
TYPES OF CONVEYERS
.Belt conveyer .Slat conveyer

.Roller conveyer 56
 CONVEYERS
.Pivoted bucket conveyer
.Trolley conveyer
.Spiral chute conveyer
Belt conveyer
TYPES OF CONVEYERS

.Belt conveyer .Slat conveyer

.Roller conveyer 57
 CONVEYERS
.Pivoted bucket conveyer
.Trolley conveyer
.Spiral chute conveyer
TYPES OF CONVEYERS

Belt conveyer

.Belt conveyer .Slat conveyer

.Roller conveyer 58
 FORK LIFT TRUCK
TYPES OF FORK LIFT

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 FORK LIFT TRUCK
TYPES OF FORK LIFT

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 FORK LIFT TRUCK
TYPES OF FORK LIFT
1.high lift platform type

2.counter balance type

T TRUC 61
 PAY LOADERS AND POWER TRUCKS

TRUCK WITH CONTAINER 62

TRACTORS AND TRACKERS

INDUSTRIAL TRACTOR
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MECHANICAL / MACHINE HANDLING CHECK LIST

.THOROUGH KNOWLEDGE OF THE OPERATION

.
GO THROUGH THE INSTRUCTION OF WARNINGS & GUIDELINES

.
MAKE THOROUGH INSPECTION BEFORE STARTING THE MACHINE

.CHECK THE CONTROLS & PROPER FUNCTIONING

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CHECK THE BRAKE,LIFTING SWITCHES,CUT OFF INDICATORS
.

CHECK ACCESS TO THE CABIN & APPROACH CAREFULLY

.CHECK GROUNDINS & PRESENCE OF PERSONS AROUND

.
CHECK THE ATTACHEMENTS PROPERLY
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 DON’T DO THE FOLLOWING

OVER LOADING IS NOT ALLOWED

DON’T JERK DURING OPERATION

PULLING OR PUSHING IS DANGEROUS

CARRYING OF PERSONS OR TRANSPORTING OF PERSONS

TAMPERING OF CONTROLS & LIMIT SWITCHES

MISUSING OR ABUSING

LOAD HANGING IS NOT PERMITTED WHILE NOT IN OPERATION

NEVER LEAVE THE CABIN WHEN THE ENGINE IS ON

IMPROPER / UNAUTHORIZED ATTACHEMENT SHOULD NOT BE USED

THE OPERATOR IS NOT PHYSICALLY OR MENTALLY FIT DON’T PERMIT HIM

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 WORK SAFELY AVOID
T ACCIDENTS T
H H
A A
N N
K K

Y Y
O O
U U
HEALTH IS WEALTH 66